Structures for use in creating artificial dentures

ABSTRACT

A structure for use in creating an artificial denture can be constructed utilizing a sheet-like self-supporting part and a plurality of simulated tooth elements. The self-supporting part is formed to include a plurality of upwardly opening pockets located in a generally U-shaped line corresponding to a line of teeth in a mouth and includes regions on both sides of this line having upper surfaces corresponding to the configuration of a mouth on both sides of such a line of teeth. The simulated tooth elements are located within the pockets so as to be exposed at the upper surface of said part. Preferably the pockets have open bottoms. The pockets are preferably interconnected; several of the tooth elements can be integral with one another.

United States Patent Kersten STRUCTURES FOR USE IN CREATING ARTIFICIALDENTURES [76] Inventor: Daniel D. Kersten, 984 Chestnut,

Escondido, Calif. 92025 [22] Filed: Aug. 14, 1972 [21] Appl. No.:280,530

[52] U.S. Cl. 32/2 [51] Int. Cl. A61c 13/00 [58] Field of Search 32/2,8, 15

[56] References Cited UNITED STATES PATENTS 3,460,252 8/1969 Schweideret a1. 32/2 3,241,238 3/1966 'Kersten 32/2 Pri r ,Etqrr in fliflertliibgg s .4 H Attorney-Edward D. OBrian [451 Jan. 8, 1-974 ABSTRACT Astructure for use in creating an artificial denture can be constructedutilizing a sheet-like self-supporting part and a plurality of simulatedtooth elements. The self-supporting part is formed to include aplurality of upwardly opening pockets located in a generally U- shapedline corresponding to a line of teeth in a mouth and includes regions onboth sides of this line having upper surfaces corresponding to theconfiguration of a mouth on both sides of such a line of teeth. Thesimulated tooth elements are located within the pockets so as to beexposed at the upper surface of said part.

Preferablythe pockets have open bottoms. The pockets are preferablyinterconnected; several of the tooth elements can be integral with oneanother.

5 Claims, 6 Drawing Figures STRUCTURES FOR USE IN CREATING ARTIFICIALDENTURES CROSS-REFERENCE TO RELATED PATENT Daniel D. Kersten US. Pat.No. 3,241,238 issued Mar. 22, 1966 entitled, Part For Use In CreatingArtificial Dentures and Process For Using the Same."

BACKGROUND OF THE INVENTION It is known that comparatively inexpensiveartificial dentures can be constructed utilizing a part serving as amold which is formed so as to include a series of simulated teeth joinedtogether by flange and diaphragmtype members corresponding in shape andconfiguration to interior regions of the mouth adjacent to a line ofteeth. Such a part is utilized in creating an artificial member byplacing a quantity of a liquid polymer material capable of hardening ina mouth within the part and then allowing this polymer material to setto a hardened state as both it and the part are located in a normaldenture location in a mouth.

During the hardening, the polymer material will attach itself to thesimulated tooth elements used and will form an artificial denture. Sucha denture is completed by stripping from the polymer material and fromthe individual teeth used the members corresponding in shape andconfiguration to the interior regions of the mouth. Either before orafter such members are stripped the denture created may be lined byplacing additional similar liquid polymer materials in it, locating itin the mouth and then allowing this additional material to harden.

As originally proposed, parts as indicated in the preceding were to beformed as integral units with simulated teeth and the memberscorresponding to the shape and configuration of a mouth joined together.The concept was that such integral parts could be molded veryinexpensively by known injection molding and similar techniques out ofvarious thermoplastic polymers. It was recognized that such polymers didnot normally have all of the physical qualities desired in along-wearing denture and that hence, the tooth elements in artificialdentures created using such parts might not wear as well as the teeth inmore conventional dentures. However, this was considered secondarybecause parts as indicated could be used to create individual denturesat such a low cost that such dentures could be used for treatmentpurposes or could be used by individualswho could not afford any moreconventional dentures.

In an effort to provide tooth elements in parts similar to thoseindicated in the preceding which would stand comparatively long wear, itwas proposed to form parts as indicated utilizing tooth elements createdfrom conventional denture-type teeth compositions secured to memberscorresponding to the shape and configuration of a mouth by an adhesive.It was similarly proposed to form tooth elements formed of suchmaterials with small grooves which could be poped or snapped intocorresponding openings in a sheet-like part corresponding in shape tointerior regions of the mouth. Although it is considered that proceduresof these types have a degree of merit, it is not considered that theyare practical from an economic standpoint because of assembly andrelated-type problems.

The need for improvement of parts as indicated so as to include withinthese parts simulated tooth elements having long-wearing and preferablynon-staining characteristics is considered to be still apparent. As willbe seen from the preceding discussion, one'aspect of this need involveseconomic considerations. More specifically there is the need to provideparts for creating artificial dentures which can be used to producedentures having long-wearing, relatively non-staining teeth at aneconomically advantageous cost.

SUMMARY OF THE INVENTION A broad objective of the present invention isto provide new and improved structures or parts of the type indicated inthe preceding discussion for producing artificial dentures. Morespecifically, an objective of the invention is to provide structures asindicated which can-but need notbe used to create artificial dentureshaving individual tooth elements of a conventional long-wearing,essentially non-staining material. A further objective of the inventionis to provide structures of the type described which can be easily andconveniently manufactured at a comparatively nominal cost. A relatedobjective of the invention is to provide structures of the typeindicated which can be economically manufactured in various differentsizes corresponding to the normal differences in shapes of human mouths.

In accordance with this invention these and various related objectivesare achieved by providing a structure for use in creating an artificialdenture which comprises a sheet-like self-supporting part shaped so asto include a plurality of upwardly opening pockets dimensioned so as tohold simulated teeth and located in a generally U-shaped linecorresponding in configuration to a line of teeth in the mouth andshaped so as toinclude regions on both sides of the line and uppersurfaces corresponding to the configuration of a mouth on both sides ofa line of teeth and a plurality of simulated tooth ele ments locatedwithin these pockets so as to be exposed at the upper surfaces of thepockets and fitting closely within the pockets.

BRIEF DESCRIPTION OF THE DRAWING A summary of this type is inherentlyincapable of in dicating many facets and features of an inventionbecause of its inherent nature. Further details of structures inaccordance with this invention and further advantages of the inventionwill be apparent from a detailed consideration of the remainder of thisspecification, the appended claims and the accompanying drawing inwhich: 7

FIG. 1 is a perspective view of a structure in accordance with thisinvention for use in creating an artificial denture to be employed withan upper jaw;

FIG. 2 is a cross-sectional view taken at line 2-2 of FIG. 1;

FIG. 3 is a partial cross-sectional view taken at line 3-of FIG. 2;

FIG. 4 is a partial cross-sectional view corresponding to FIG. 3 of amodified structure in accordance with this invention; FIG. 5 is aperspective view corresponding to FIG. 1 of a structure in accordancewith this invention which has the .same parts as the structure of FIG.1, but which is shaped for use in creating an artificial denture to beemployed with a lower jaw; and

FIG. 6 is a diagrammatic cross-sectional view indicating how a structureas herein described may be formed.

The accompanying drawing is primarily intended for explanatory purposes.It shows several presently preferred forms or embodiments of structuresin accordance with this invention utilizing theessentially intangibleconcepts of the invention defined in the appended claims. These conceptsmay be employed in other somewhat differently appearing and somewhatdifferently constructed structures through the use of routineengineering skill in the field of artificial dentures and relatedstructures.

DETAILED DESCRIPTION In FIG. 1 of the drawing there is shown a structurein accordance with this invention which, as indicated by the precedingbrief description, is intended to be utilized in creating an artificialdenture to be employed with an upper jaw. This structure 10 employs asheetlike self-supporting part 12 and a series of simulated toothelements 14. This part 12 is preferably formed out of a self-supportingmaterial which does not readily bond to liquid resins capable of beingutilized increating artificial dentures by the series of steps indicatedin the preceding discussion relative to the background of the invention.

Thus, this part 12 can conveniently be formediof a polyolefin such aseither low or high density polyethylene or a large number of otherphysically similar or equivalent polymer materials. It preferably shouldbe imporous in nature so that there is no danger of a liquid polymercomposition flowing through it as it is utilized. Preferably this part12 should be somewhat flexible so that it is capable of deforming to aslight extent as it is utilized within the mouth to avoid unduediscomfort to an individual. Also, when the part 12 is somewhat flexbileit is possible to bend of deform it slightly to conform to a desiredconfiguration.

The tooth elements 14 used preferably are of a ceramic or ceramic-typematerial as is conventionally utilized in the construction of artificialdentures. It will be recognized that such materials are well-known; thatthey are physically hard enough to withstand prolonged use in dentures;and that they are substantially immune to discoloration during normaluse. These tooth elements 14 are preferably shaped in different mannersso as to have lower surfaces 16 to be exposed in a denture whichcorresponds in shape and configuration to a normal set of teeth within amouth.

No effort is made in this specification or in the drawing to indicatethe names of various different teeth to be simulated by the surfaces 16and/or their configuration since these are matters considered to bewellknown in the dental field. The important thing to note is that thetooth elements 14 vary in shape and configuration in accordance withwhat may be referred to as a normal pattern.

These tooth elements 14 have upper surfaces 18 which are normallyexposed at the top of the structure 10. These upper surfaces 18 may beof any convenient shape for bonding to a liquid resin in creating anartificial denture. Preferably these upper surfaces 18 should includeholes 20 located at angles to one another in the structure 10, and/orsurface irregularities 22 such as notches so that any liquid resin usedwill form. a firm mechanical interlock between the elements 14 and thesolidified resin in a complete denture.

Expedients necessary to create such a mechanical interlock are notnecessary if the resin employed is of such a character that it will forma firm adhesive type of bond. Since a number of factors may interferewith such a bond it seems preferable to use expedients as indicated tocreate the mechanical interlock even in those cases where it is feltthat an adhesive or chemicaltype bond will adequately secure an element14 in an artificial denture. It is considered that the need for such ameans or expedient to create a mechanical interlock is not as pronouncedas when normal, conventional may be interconnected by what may bereferred to as grooves 26 extending between their adjacent sides.

These pockets 24 are preferably arranged in a line as shown in FIG. 1corresponding to a line of normal teeth within a mouth so that they arespaced in approximately the same manner as normal teeth. These pockets24 are alsoof a depth such that the upper surfaces 18 of the toothelements 14 are exposed to approximately the same extent.

Preferably the pockets 24 are formed as shown so as to have open bottoms25 located adjacent to and around the portions of the tooth elements 14which will abut against opposing teeth in a mouth. The significance maynot be readily apparent. As a structure such as the structure 10 is usedit is employed with a liquid resin as indicated in the precedingdiscussion and this entire structure is placed within'the mouth and heldin this location as the resin sets up so as to create what becomes acompleted denture after removal of the part 12.

If the pockets 24 did not have these open bottoms 25 the spacingachieved with the structure 10 in the mouth would not correspond asaccurately as reasonably possible to an intended natural type of spacingdesired in an artificial denture. This matter of spacing becomessignificant when both upper and lower dentures are to be created at thesame time since if the structures to be used in creating such upper andlower dentures were to be spaced apart by the thicknesses of two of theparts 12 at the bottoms of the pockets 24, the denture might not fit asaccurately as desired. However, it is to be understood that dentures canbe created using structures such as the structure 10 using the pockets24 having bottoms.

The part 12 also includes inner and outer regions 28 and 30 having uppersurfaces 31 corresponding in shape to the shape of the regions of themouth adjacent to a line of teeth. Although exact correspondence inshape may be preferred because of the effect on the appearance of anultimate denture, satisfactory results can be obtained when there isonly an approximate correspondence between the shape of these uppersurfaces and internal surfaces within the mouth. It is possible to labelthese regions 28 and 30 with reference to standard dental terminology.It is not considered that it is necessary to utilize this terminology inexplaining this invention since the purpose of this specificationrelates in the drawing and in the preceding discussion. If desired, theymay be held in place by a tacky pressuresensitive adhesive or the likeso that they will not fall out of these pockets 24, although this is notnormally considered necessary. Preferably these pockets 24 fit closelyenough adjacent to the tooth elements 14 so that they will be-held inplace by friction in such a manner that liquid resin will not permeatethe pockets 24 adjacent to the lower surfaces 16 when the structure isutilized as indicated in the preceding discussion.

When the tooth elements 14 are formed to simulate conventional teeth,the configuration of the pockets 24 will be such that a minor amount ofa snap type action involving temporary deformation of the pockets 24will be necessary to insert them in the part 12. If desired, individualtooth elements 14 may be formed so that their lower surfaces 16 may beslightly enlarged beyond a normal appearance so that they have to besnapped into the pockets 24 with significant material deforma tion sothat they will be firmly held in position. This type of expedient isconsidered preferred in making sure that the tooth elements 14 are heldso that they will not fall out of place during normal handling and thelike.

If desired, the structure 10 may include aligned or substantiallyaligned notches 32 in the upper surfaces 18 of the individual elements14. These notches 32 preferably, but not necessarily are formed so thattheir entrances are slightly smaller than their bottoms so that adeformable wire 34 such as a stainless steel wire may be securly wedgedwithin them. This wire 34 helps hold the tooth elements 14 in thedesired configuration.

More important, however, is its function of enabling the structure 10 tobe adjusted to a moderate or slight amount to accommodate variation inhuman mouths. This wire 34 may be easily bent by a dentist tosubstantially the shape of a line of teeth desired in a particulardenture and may be utilized to hold the elements 14 to such a shape.This will normally involve the wire 34 holding the part 12 soit isslightly bent or deformed from its original configuration;

In FIG. 4 of the drawing there is shown a modified structure 40 which isessentially similar to the structure 10. In the interest of brevitythose parts of the structure 40 which are the same orsubstantially thesame as the parts employed in the structure 10 are not separatelydescribed herein and are designated in the remainder of thisspecification and in the drawing by the primes of the numeralspreviously used.

In the structure 40 several of the individual tooth elemerits 14' arejoined together by bridges 42 connecting their upper surfaces 18'. Ifdesired, all of these tooth elements 14 can be so connected. It will benoted that the bridges 42 extend generally within and above the groove26' in locations where they would be hidden by the polymer material usedin creating dentures. This type of expedient is considered desirable infacilitating the assembly and manufacture of the complete structure 10.

In FIG. 5 of the drawing there is shown what technically is a modifiedstructure 50 of the present invention. in actuality this structure 50 isidentical to the structure 10 except for the fact that it is shaped soas to be employed in creating what may be referred to as a lowerartificial denturefln the interest of brevity, no parts of thisstructure 50 are separately described herein.

Various parts of this structure 50 which are the same or substantiallythe same as parts of the structure 10 are designated in the drawing bythe same numerals used to designate parts of the structure it). From aconsideration of FIG. 6 it will be realized that the terms upper andlower used and described in connection with the structure 10 are merelyused in a relative sense for con venience of designation. These termshave been used primarily with reference to the way an individualstructure will appear as it is normally handled.

Structures such as the structures 10, 40 and 50 may be easilymanufactured with a minimum of difficulty by utilizing what may bereferred to as a lower vacuum forming mold 60 as indicated in FIG. 6 ofthe drawing. This mold has a porous mold body 62 having an upper surface64 corresponding in shape to the upper surfaces 31 described and havingindividual cavities 66' corresponding to 'the upper surfaces 18 of thetooth elements 14 as they will appear'in the structure 10 (or in theother structures shown).

The individual tooth elements 14 to be used in such a structure arelocated upside down within these cavities 66 and then a sheet 68 of athermoplastic material to be used to form a part 12 may be located overthem and over the mold'60 in a heated, softened state. This sheet 68 maythen be pulled down by a vacuum drawn through the mold 60 so as to ineffect form a package or skin around the lower surfaces 16 defining thepockets 24. As the sheet 68 is handled in this manner the entire part 12will be formed. After the sheet 68 has been cooled the resultant productmay be trimmed in accordance with conventional practice so as to form astructure such as the structure 10*.

It is preferred, however, to furtherprocess such a resultant structureso as to remove the bottoms of the pockets 24 created in the areas wheresurfaces of the tooth elements will abut against opposing teeth orartifical tooth elements. Such removal can be accomplished in a numberof different ways in accordance with conventional practice. The sheet 68may be cut using appropriate manipulative tools such as a hand tool or apanograph equipped with. a rotary cutter to remove the bottoms of thepockets created. It is even considered possible to remove the bottoms ofthese pockets 24 by various solvent techniques when the sheet 68 isformed of a polymer material which is soluble in a solvent by merelylocating the structure produced so that its bottom rests in the solventso that the solvent will place the contacted parts of the sheet 68 insolution.

I claim 1. A structure for use in creating an artificial denture whichcomprises: a a sheet-like self-supporting part shaped so as to include aplurality of upwardly opening pockets having open bottoms dimensioned soas to hold simulated teeth and located in a generally U-shaped linecorresponding in configuration to a line of teeth in the mouth andshaped so as to include regions on both sides of said line having uppersurfaces corresponding to the configuration of a mouth on both sides ofa line of teeth, and a plurality of simulated tooth elements locatedwithin said pockets, said tooth elements being exposed at the uppersurface of said part and fitting closely within said pockets so thatduring the use of said structure a liquid resin used with said structurewill not permeate between said tooth elements and the interiors of saidpockets to any significant extent,

said part being formed of a polymer composition incapable of bonding toa polymer composition to be used with said structure and said toothelements are formed of a composition capable of bonding to such apolymer composition to be used with said structure,

said pockets and said tooth elements being of such a dimension and shapethat said tooth elements are held in place in said pockets by engagementwith said pockets.

2. A structure as claimed in claim 1 including:

a deformable wire secured to each of said tooth elements and extendinggenerally along said line.

3. A structure as claimed in claim 1 wherein:

said tooth elements include on the surfaces of said tooth elementsexposed in said structure means for forming a mechanical interlock witha polymer composition.

4. A structure as claimed in claim 1 wherein:

at least some of said tooth elements are connected to one another so asto facilitate assembly of said structure.

5. A structure as claimed in claim 1 wherein:

said tooth elements are formed of a ceramic composition capable ofserving in an artificial denture without significant staining, and

each of said tooth elements includes a notch in the portion of itnormally exposed at the surface of said part,

and including,

a deformable wire secured in each of said notches so as to secure saidtooth elements to one another.

1. A structure for use in creating an artificial denture whichcomprises: a sheet-like self-supporting part shaped so as to include aplurality of upwardly opening pockets having open bottoms dimensioned soas to hold simulated teeth and located in a generally U-shaped linecorresponding in configuration to a line of teeth in the mouth andshaped so as to include regions on both sides of said line having uppersurfaces corresponding to the configuration of a mouth on both sides ofa line of teeth, and a plurality of simulated tooth elements locatedwithin said pockets, said tooth elements being exposed at the uppersurface of said part and fitting closely within said pockets so thatduring the use of said structure a liquid resin used with said structurewill not permeate between said tooth elements and the interiors of saidpockets to any significant extent, said part being formed of a polymercomposition incapable of bonding to a polymer composition to be usedwith said structure and said tooth elements are formed of a compositioncapable of bonding to such a polymer composition to be used with saidstructure, said pockets and said tooth elements being of such adimension and shape that said tooth elements are held in place in saidpockets by engagement with said pockets.
 2. A structure as claimed inclaim 1 including: a deformable wire secured to each of said toothelements and extending generally along said line.
 3. A structure asclaimed in claim 1 wherein: said tooth elements include on the surfacesof said tooth elements exposed in said structure means for forming amechanical interlock with a polymer composition.
 4. A structure asclaimed in claim 1 wherein: at least some of said tooth elements areconnected to one another so as to facilitate assembly of said structure.5. A structure as claimed in claim 1 wherein: said tooth elements areformed of a ceramic composition capable of serving in an artificialdenture without significant staining, and each of said tooth elementsincludes a notch in the portion of it normally exposed at the surface ofsaid part, and including, a deformable wire secured in each of saidnotches so as to secure said tooth elements to one another.